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Mercruiser 3.0 service manual pdf download. Mercury Mercruiser Marine Engine PDF Service Manual
OnlineFamily protonmail. There's an old manual in the boat, badly mold-damaged. Greg McDonald Saturday, 26 December Is there an earlier version manual or does the manual 26 cover this earlier version that I have? Thomas Johnston Wednesday, 18 November Hi can you please send me information on my Old Mercury red band out board that is still running good Sn I need a work shop manual for this motor. My email is ivbinfshn gmail.
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Downloaded: Melhor site de filmes para download. Congo gospel music downloads. Driver universali scanner windows 7. Hp deskjet d printer driver free download for windows 7 32bit. Abertura cavaleiros do zodiaco download. To ensure compliance with emission regulations, use only Mercury MerCruiser replacement parts. Remove the engine information plate. Remove the PCV valve. If inspecting the valve with the engine stopped: Disconnect the PCV valve from the hose.
Shake the PCV valve. If you hear a metallic rattle, the valve is functional. If you do not hear the rattle, replace the valve. Inspect the muffler for holes, cracks, or deterioration. Replace if damaged. If fuel is ever visible in the tube, see your authorized Mercury MerCruiser dealer to replace the fuel pump. Completely retract the end of the steering cable before applying lubricant.
NOTE: If steering cable does not have grease fitting, inner wire of cable cannot be greased. Page Manual Steering System 3. Lubricate the steering pin. On dual engine boats: Lubricate the tie bar pivot points. Tube Ref. Page Throttle Cable 1. Lubricate the pivot points and the guide contact surfaces. Never operate the boat out of the water with a propeller installed. Before installing or removing a propeller, place the drive unit in neutral and engage the lanyard stop switch to prevent the engine from starting.
Slide thrust hub onto propeller shaft, with stepped side toward propeller hub. Loosen power steering pump attaching bolts and mounting bolts. Pivot power steering pump toward engine, as required, until belt can be removed.
See Sterndrive Water Pickups following for the flushing procedure. Consult your authorized Mercury MerCruiser dealer for further explanation. Side pickups require the flushing attachment Q 2. Do not operate the engine above RPM out of the water and without sufficient cooling water supply. Page 87 Section 5 - Maintenance Mercury MerCruiser power packages are equipped with anodes to help protect them from galvanic corrosion under moderate conditions.
However, for severe conditions i. System should be tested to ensure adequate output. The test should be performed where boat is moored, using Quicksilver Reference Electrode and Test Meter. For additional assurance against freezing and rust, after draining, fill the seawater cooling system with propylene glycol mixed to the manufacturer's recommendation to protect engine to the lowest temperature to which it will be exposed during freezing temperatures or extended storage.
Remove the boat from the water or close the seacock, disconnect and plug the seawater inlet hose, and ensure the bilge pump is operational before draining.
Push the quick connect fitting release buttons and remove the blue drain hoses from the bracket. Page 98 Section 6 - Storage 1. If draining with the boat in the water, close the seacock if equipped or remove and plug the water inlet hose.
If draining with the boat out of the water, place the boat on a level surface to ensure complete draining of the system. Page 99 Section 6 - Storage 4. Remove and lower the hose connecting the water inlet to the power steering cooler, or the water inlet to the heat exchanger. Ensure that the speedometer pitot hole, gear housing water vent and drain holes, and trim tab cavity vent and drain holes are open and unobstructed.
Page Section 6 - Storage 3. Ensure the clogged blue drain hose is in the correct position below its connection point on the block. Cable or helm partially frozen from rust or corrosion; cable over-lubricated; improper cable installation Refer to appropriate Sterndrive Service Manual Causes loss of pressure Special Information Worn, broken or out of adjustment. Binding in sterndrive unit Restriction in hydraulic hoses Control valve not positioned properly, not balanced properly, or the mounting nut is loose Mounting bracket adjusting screw loose or mounting tube is loose Faulty pump.
Worn piston ring or scored housing bore in Causes loss of pressure cylinder Leaking valve body or loose fitting spool.
Noisy Pump Cause Drive belt Low fluid level Air in fluid Faulty pump Restricted fluid passages Stop nut adjusted improperly Steering cables installed that do not meet BIA standards Air leak in lines, pump, or air form installation Use stethoscope to listen for noise in pump Kinks or debris in hoses or debris in passages Refer to appropriate Sterndrive Service Manual Refer to appropriate Sterndrive Service Manual Special Information Check belt tension.
Insufficient Water Flow From Alpha One Sterndrive Unit Seawater Pickup Pump Cause Seawater shutoff valve partially or fully closed if equipped Water pickup clogged with foreign material Kinked or broken bell housing to gimbal housing water tube hose Corroded through gimbal housing water tube Water pickup inserts warped. Engine will overheat while boat is underway. Water pickup must not protrude above gear housing surface or inserts will create an irregular or turbulent water flow over the water pickup holes.
Consequently, this may cause loss of cooling water and subsequent engine overheating. This condition can be identified by cavitation burn pitting or erosion on the gear housing in the area aft of the water pick up. An object or an irregularity on boat or gear housing in area close to to water pickups could create turbulence in water flow going to water pickups. This could aerate the water flow and cause engine to overheat Special Information.
Damaged gear housing or accessories improperly installed on boat bottom or transom speedometer pick up, depth sounder transducer, etc. Substantial amount of barnacles or other marine growth on gear housing or boat bottom. Engine will overheat while underway only. Sterndrive installed too high on transom or Contact boat company if sterndrive is too drive unit trimmed out too far out allowing high.
Instruct operator on proper trimming air to be drawn into pump. Engine will technique if unit is trimmed out too far. Water passage in driveshaft housing improperly drilled To check cross drilled water passages in driveshaft housing, remove plug and pipe plug located under decal on starboard side of housing. Drive unit must be shifted into reverse to remove pipe plug. Table of Contents Torque Specifications.
Engine Removal. Refer to Sterndrive Service Manual. Remove instrument harness connector plug from engine harness receptacle after loosening clamp. Gasoline is extremely flammable and highly explosive under certain conditions. Do not smoke or allow spark or open flame in area. Disconnect and plug fuel line to prevent fuel in tank from leaking into bilge. Disconnect bullet connectors of trim sender wires coming from transom assembly from engine harness. Disconnect MerCathode wires from MerCathode controller if equipped.
Disconnect seawater inlet hose from gimbal housing. Loosen hose clamps and disconnect exhaust elbow hose. Remove both shift cables from shift plate. Retain locknuts and hardware. Disconnect and suitably plug fluid hoses from power steering control valve on transom. DO NOT use to lift entire engine.
Support engine with suitable sling through lifting eyes on engine and remove front and rear engine mounting bolts.
Retain hardware. Carefully remove engine. DO NOT hit power steering control valve. Installation Engine Installation 1. Be certain fiber washers cemented in place on inner transom plate are present.
Inspect fiber washers. Replace if worn or damaged. Install double wound lockwashers onto inner transom plate inside fiber washer. Be certain rear engine mount locknuts are in position as shown. Lubricate exhaust bellows with soap and water to ease installation. Attach a suitable sling to lifting eyes on engine and adjust so that engine is level when suspended. Align rear engine mounts with inner transom plate mounts while simultaneously aligning exhaust tubes with exhaust pipe hoses bellows.
Do not fasten attaching hardware until you have aligned engine. Install both rear engine mounting bolts and hardware as shown. Torque mounting bolts to 38 lb-ft 52 Nm. Shift cable outer casing can be crushed causing difficult or improper shifting. Set engine down on stringers and relieve hoist tension. Disconnect sling from engine lifting eyes and switch sling to center lifting eye. Attempt to insert solid end of Quicksilver Alignment Tool through gimbal bearing and into engine coupler splines.
Relieve hoist tension entirely and fasten both front mounts to boat stringer using appropriate hardware lag bolts or through-bolts, etc. Recheck alignment with alignment tool. Tool must enter coupler splines freely. If not, readjust front mounts. When alignment is correct, tighten locknut or nut with lockwasher on each mount securely. Remove alignment tool if not already removed. Tighten all exhaust system clamps securely as shown use two clamps on each connection.
Connect seawater inlet hose to water tube at gimbal housing with hose clamp. Tighten clamp securely. Connect instrument harness to engine harness with clamp. Connect fuel line from fuel tank s to engine. Make certain connections are secure. Check for leaks. Connect throttle cable using hardware retained and adjust as follows: a. DO NOT fasten any items to throttle cable. Outer cable must be free to move when cable is actuated.
Install cable end guide on throttle lever, then push cable barrel lightly toward throttle lever end. This will place a slight preload on cable to avoid slack in cable when moving remote control lever. Adjust barrel on throttle cable to align with anchor stud. Secure throttle cable with hardware retained as shown.
Tighten cable end guide locknut until it contacts and then loosen one full turn. Tighten throttle cable anchor screw securely. Place remote control throttle lever in the wide-open-throttle W. Ensure that throttle shutters valves are completely open and throttle shaft lever contacts carburetor body casting.
Return remote control throttle lever to idle position and ensure that throttle lever contacts idle speed adjustment screw. Accessory ground wires should only be attached to ground stud on engine.
Connect any grounding wires or accessories that have been disconnected. Connect MerCathode wires to MerCathode controller assembly as shown, if equipped. Apply a thin coat of Quicksilver Liquid Neoprene to all connections. Refer to appropriate Sterndrive Service Manual. Install and adjust drive unit and remote control shift cables, using hardware retained. Connect power steering fluid hoses to control valve large fitting first as shown.
This will help avoid stress on the hose fittings and will help avoid kinks in the hose. Torque fittings to 23 lb-ft 31 Nm. Tighten clamps securely. NOTE: Spray terminals with a battery connection sealant to help retard corrosion.
Rocker Arm Studs. Valve Guide Bore Repair. Valve Springs - Checking Tension. Valve Seats. Dipstick Specifications. All Engines. Oil Pan. Oil Pump. Cleaning and Inspection. Torsional Damper.
Crankcase Oil Seal. Crankcase Front Cover. Flywheel and Engine Coupler. Rear Main Oil Seal. Main Bearings. Checking Clearances. Main Bearing Replacement.
Connecting Rod Bearings. Inspection and Replacement. Table of Contents continued Crankshaft. Crankshaft Sprocket. Measuring Lobe Lift. Camshaft Gear Replacement. Cylinder Block. Oil Filter By-Pass Valve. Inches Millimeters Model Displacement 3. Production No.
Camshaft Lobe Lift Max. Cylinder Head Gasket Surface Flatness. General Some of the repairs in this section must be completed with engine removed from boat. Engine removal depends upon type of repair and boat design. Place engine on repair stand for major repairs. When engine removal is not required, make certain that battery cables are disconnected at the battery prior to performing any on-board engine repair procedure.
Lubricate all moving parts during reassembly with engine oil. Apply Quicksilver Perfect Seal on threads of and under heads of cylinder head bolts, and on threads of all cylinder block external bolts, screws and studs. Model MCM 3. This code number is stamped on all MerCruiser power packages and replacement partial engines, but not replacement cylinder block assemblies.
Engine Code Location 3. Engine Rotation Engine rotation terminology at times has caused confusion. To clarify, engine rotation is determined by observing flywheel rotation from the rear transmission or sterndrive end of the engine looking forward water pump end. Remote Starter Kit A1 1. Fill crankcase to proper level with the recommended engine oil. Leave ignition key in OFF position. If remote starter switch is not available, disconnect PURPLE wire from ignition coil before using key switch to crank the engine over.
Install spark plugs and wires 9. Piston Failures Pre-Ignition Pre-ignition is abnormal fuel ignition, caused by combustion chamber hot spots. Control of the start of ignition is lost, as combustion pressure rises too early, causing power loss and rough running.
The upward motion on the piston is opposed by the pressure rise. This can result in extensive damage to the internal parts from the high increase in combustion chamber temperature.
Overheated spark plug electrodes improper heat range or defective plug. Any other protuberance in the combustion chamber, such as an overhanging piece of gasket, an improperly seated valve or any other inadequately cooled section of material which can serve as a source. Engine failures that result from the foregoing conditions are beyond the control of Mercury Marine. No warranty will apply to failures which occur under these conditions. Detonation Detonation, commonly called fuel knock, spark knock or carbon knock, is abnormal combustion of the fuel which causes the fuel to explode violently.
The explosion causes overheating or damage to the spark plugs, pistons, valves and, in severe cases, results in pre-ignition. Use of low octane gasoline is one of the most common causes of detonation. Even with high octane gasoline, detonation could occur if engine maintenance is neglected.
Over-advanced ignition timing. Lean fuel mixture at or near full throttle could be caused by carburetor or leaking intake manifold. Cross-firing spark plugs. Inadequate cooling of engine by deterioration of cooling system.
Engine failures that result from the foregoing conditions are beyond the control of MerCruiser. Rocker Arm Cover Removal It may be necessary to remove exhaust manifold before removing rocker arm cover. Disconnect crankcase ventilation hose. Remove any items that interfere with the removal of rocker arm covers.
Gaskets, which may adhere to cylinder head and rocker arm cover, may be loosened by bumping end of rocker cover from the rear with palm of hand or a rubber mallet. Remove rocker arm cover. Installation 1. Clean sealing surfaces on cylinder head and rocker arm cover with degreaser.
Place new rocker arm cover gasket in position in rocker arm cover. Install rocker arm cover. Torque bolts to 40 lb-in. Install exhaust manifolds. Install any items which were removed to allow removal of rocker arm covers. Connect crankcase ventilation hose to rocker arm cover. Push Rod Cover Removal 1. Remove the pushrod cover bolts. Remove the pushrod cover. Remove the gasket. Clean sealing surfaces on pushrod cover with degreaser. Install new pushrod cover gasket in position. Install pushrod cover.
When servicing all rocker arms, bring No. Remove rocker arm covers as outlined. Remove rocker arm assemblies and push rods. Cleaning and Inspection 1. Clean parts with solvent and dry with compressed air. Inspect all contact surfaces for wear. Replace all damaged parts. Install push rods in their original locations. Be sure push rods seat in lifter socket. Install rocker arms, rocker arm balls and rocker arm nuts in their original locations. Adjust carburetor idle speed and mixture.
Valve Adjustment Engine Not Running With valve cover removed, adjust valves when lifter is on low part of camshaft lobe, as follows: 1. Crank engine with starter or turn over in normal direction of rotation until mark on torsional damper lines up with center 0 mark on timing tab, and engine is in No.
This may be determined by placing fingers on No. If valves move as mark comes up to timing tab, engine is in No. With engine in No. Loosen adjusting nut until lash is felt at push rod, then tighten adjusting nut until all lash is removed. This can be determined by moving push rod up and down while turning adjusting nut until all play is removed.
Valve lash should be checked after engine has run and reached operating temperature. Crank engine one revolution until pointer 0 mark and torsional damper mark are again in alignment.
This is No. With engine in this position, the following valves may be adjusted: No. Repeat steps to adjust other valves. Install Distributor cap, spark plug wires and coil lead. Install rocker arm cover; torque to 40 lb-in. Engine Running Following procedure should be completed only if readjustment is required. Run engine until it reaches normal operating temperature, then remove valve cover. With engine running at idle, loosen valve rocker arm nut until valve rocker arm starts to clatter.
Turn rocker arm nut down slowly until clatter just stops. This is zero lash position. Repeat Steps to adjust other valves. Install rocker arm cover, torque to 40 lb-in. Adjust carburetor idle mixture and idle speed. Hydraulic Valve Lifters Hydraulic valve lifters require little attention. Lifters are extremely simple in design. Normally, readjustments are not necessary and servicing requires only that care and cleanliness be exercised in the handling of parts. Locating Noisy Lifters Locate a noisy valve lifter by using a piece of garden hose approximately 4 ft 1.
Place one end of hose near end of each intake and exhaust valve, with other end of hose to the ear. In this manner, sound is localized, making it easy to determine which lifter is at fault.
Another method is to place a finger on face of valve spring retainer. If lifter is not functioning properly, a distinct shock will be felt when valve returns to its seat. General types of valve lifter noise are as follows: 1.
Hard rapping noise - usually caused by plunger becoming tight in bore of lifter body so that return spring cannot push plunger back up to working position. Probable causes are: Excessive varnish or carbon deposit, causing abnormal stickiness. Galling or pickup between plunger and bore of lifter body, usually caused by an abrasive piece of dirt or metal wedged between plunger and lifter body.
Excessively high leakdown rate. Leaky check valve seat. Improper adjustment. General noise throughout valve train - this will, in most cases, be a definite indication of insufficient oil supply or improper adjustment. Intermittent clicking - probable causes are: A microscopic piece of dirt momentarily caught between ball seat and check valve ball. In rare cases, ball itself may be out of round or have a flat spot.
In most cases, where noise exists in one or more lifters, all lifter units should be removed, disassembled, cleaned in solvent, reassembled and reinstalled in engine. If dirt, corrosion, carbon, etc. It would only be a matter of time before all lifters caused trouble. Removal 1. Remove as previously outlined: a. Rocker arm covers. Push rod cover. IMPORTANT: Keep valve push rod and hydraulic lifter from each valve together as a matched set and mark or store them so they can be reinstalled in the same location later.
Rocker arm assemblies and push rods. Make matching marks on all lifters as to location and orientation in bores, to allow reassembly in exact position on camshaft lobes so that the rollers bearing and roller will roll in the same direction on the same lobe, if reused. Remove valve lifters. Thoroughly clean all parts in cleaning solvent and inspect them carefully. If any parts are damaged or worn, entire lifter assembly should be replaced. If outer lifter body wall is scuffed or worn, inspect cylinder block lifter bore.
If push rod seat is scuffed or worn, inspect push rod. If new lifters or a new camshaft have been installed, an additive containing EP lube such as General Motors Cam and Lifter Prelube or equivalent should be poured over camshaft lobes before installing lifters. Install valve lifters into bores. Install push rod cover, using new gaskets and torque to specification. Install distributor, positioning rotor to number 1 cylinder position, then connect primary lead at coil.
Install distributor cap and spark plug wires. Adjust valves to specifications. Install rocker arm cover, torque tp 40 lb-in. Adjust ignition timing, carburetor idle speed and mixture. Replacing Oil Seal Head Installed 1. Remove spark plug, rocker arm and push rod on cylinder to be serviced. Place piston for that cylinder at TDC to prevent valves from dropping into the cylinder.
Compress valve spring with tool J and remove valve keys, valve spring cap, spring shield and valve spring.
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